With advanced semiconductor technologies continuing to evolve, defect prediction has experienced increased challenges because process issues involve complex interactions of multiple-layer layout patterns. This makes it more challenging than before for traditional pattern search techniques to identify, predict, and fix the process issues in a short time. Also, due to the increased cycle time to introduce new semiconductor technologies, for Integrated Circuit (IC) design houses with early technology engagements, finding potential defects in these new technologies and improving design quality become more challenging than before. Oftentimes utilization of previous learning experience for detecting and reducing defects becomes unavoidable. To overcome these difficulties, a feature-based artificial intelligence/machine learning (AI/ML) defect prediction tool has been developed and utilized to improve the prediction of potential process defects for IC designs. With this tool and its workflow, with the previous technology process improvement learning experience, the defect patterns are generated to improve design qualities for the new technology. The tool also provides functions of clustering and compressing the predicted defect patterns that facilitate finding root causes of the process defects. This paper will describe the new defect prediction flow, especially using previous technology process improvement data to analyze similar issues in the current technology designs.
As the process development advances to deep sub-100 nm technology, many new
technologies such as immersion lithography and hyper NA lens design are developed for
the improved on-wafer pattern resolution to meet the technology requirement. During the
early process development such as 45 nm technology, it was not clear that lithography
tool could meet stringent CD variation requirement. Many rules such as fixed poly pitch,
single poly orientation, and dummy poly insertion for diffusion edge transistors were
implemented [1, 2] to ensure that, with designated litho-tool, the CD variation control
could be minimized. These rules generally added layout design complexity and area
penalty. It would be efficient that these rules could be evaluated and properly
implemented with data collected from well-design test structures.
In this work, a set of simple test structures with various dummy poly gate lengths
and numbers of dummy poly gates, and fix-pitch poly gate orientations were
implemented in the process development test vehicles (TV's). Electrical, simulation, and
in-line CD data of these test structures were collected. Analysis of the data and related
design rule optimization and implementation are described. This work helped to optimize and to properly implement the 45 nm gate poly
design rules during early process development for Xilinx FPGA product development.
As transistor dimensions become smaller, on-wafer transistor dimension variations, induced by
lithography or etching process, impact more to the transistor parameters than those from the earlier process
technologies such as 90 nm and 130 nm. The on-wafer transistor dimension variations are layout dependent
and are ignored in the standard post layout verification flow where the transistor parameters in a spice
netlist are extracted from drawn transistor dimensions. There are commercial software tools for predicting
the on-wafer transistor dimensions for the improved accuracy of the post-layout verification. These tools
need accurate models for the on-wafer transistor dimension prediction and the models need to be
re-calibrated as the fabrication process is changed. Furthermore, the model-based predictions of the
on-wafer transistor dimensions require extensive computing power which can be time consuming.
In the paper, a procedure to back-annotate the process induced transistor dimension changes into the
post layout extracted netlist using a simple look-up table is described. The lookup table is composed of
specified drawn transistor and its sounding layout as well as their on-wafer dimensions. The on-wafer
dimensions can be extracted from simulations, SEM in-line pictures or electrical data of specially designed
testkeys. Taking the lookup table data, accordingly, the transistor dimensions in the post-layout netlist file
are then modified by a commercial software tool with a pattern search function. Comparing with the
model based approach, the lookup table approach takes much less time for modifying the post-layout netlist.
The lookup table approach is flexible, since the tables can be easily updated to reflect the most recent
process changes from the foundry.
In summary, a lookup table based approach for improving the post-layout verification accuracy is
described. This approach can improve the verification accuracy from both litho and non-litho process
variations. This approach has been applied to Xilinx's 65 nm and 45 nm product developments.
We describe design house approaches for design rule developments with emphasis of valuations of pre-optical proximity correction (pre-OPC) layouts and their simulation results. To begin, we describe the procedure of the simulation model calibration. An evaluation of metrics for analyzing the design layouts is then described. Due to the unavailability of post-OPC layouts, both pre-OPC and trial-OPC simulations are studied. A range of layout pattern density, within which the pre-OPC metric follows the post-OPC's, is estimated. Within this pattern density range, pre-OPC layout then can be evaluated to identify potential process "hot spots." With this approach, a set of design for manufacturability (DFM) compliance design rules is derived and applied to the product developments for both 90- and 65-nm process technology nodes. Several hot spots in the products (designed with 90-nm design rules) are located and fixed using layout optimization guided by the DFM rules. Simulated image contours and in-line scanning electron microscope (SEM) images validate the approach.
A new method to calibrate optical lithography model using a combination of
measured Critical Dimension (CD) data from the standard patterns and product layout
SEM pictures have been developed. The CD data is composed of the measured CDs of
through-pitch line patterns as well as isolated line and isolated space patterns. The SEM
pictures for contour CD calibrations are from the product layouts. The small set of 1-D
CD data is firstly used to calibrate the model. After best one-dimensional (1-D) data
calibration accuracy is achieved, the model is used to predict the contour of the product
layouts where the SEM pictures are taken. The simulated contours are overlaid with the
SEM pictures to identify the mismatch locations. Additional calibration gauges at the
locations are then added to the model to improve the predicted CD accuracy of 2-
dimensional (2-D) patterns such as line-to-tip, tip-to-tip, and corner. In comparison with
the SEM picture CDs, this procedure can be repeated several times until desired accuracy
of the predicted contours is achieved. This method can increase the model's 2-D edge
prediction accuracy and can reduce the amount of CD data required for model calibration.
This calibration method is used to generate the models for lithography process
simulations for Xilinx's 65 nm product developments. Hot spots and out-of-spec OPC
CD locations are identified using the models and later confirmed from in-line data.
In this paper we describe, from the user's point of view, how Inverse Lithography Technology (ILT) differs from Optical Proximity Correction (OPC). We discuss some specifics of ILT at chip-scale. We show simulation and experimental results from 90nm and 65nm semiconductor nodes, comparing results from ILT-generated masks and OPC-generated masks for real-life layouts, in a production environment. In addition, we discuss issues related to complexity and manufacturability of ILT-generated masks.
As the advent of advanced process technology such as 90-nm and below, the design rules become more and more complicated than before. These complicated design rules can guarantee process margin for the most layout environments. However, some layouts have narrow process windows that were still within the design rules. For example, line end layouts in a dense environment would generally have narrower process window than that of the onedimensional (1-D) dense line environment. The dense line end spacing design rule would be larger than that of the 1-D dense line spacing to compensate for the narrow window effect. In this work, an optical simulation software was used to examine an existing 90-nm FPGA product pre-OPC layout for its optical contrast. The optical contrast could correlate to the depth of focus (DOF) process window. Several back end locations were identified with possible narrow DOF windows. From the evaluations of these low contrast patterns, several design for manufacturing (DFM) rules and DRC deck was then developed. This deck
effectively identified the narrow process window layout locations, previously found with the simulation software. These locations were then optimized for the improved DOF windows. Both simulation and in-line data showed that the DOF window was improved after the layout optimization. Product data with optimized layouts also showed the improved yield.
In the post-physical verification space called 'Mask Synthesis' a key component of design-for-manufacturing (DFM), double-exposure based, dark-field, alternating PSM (Alt-PSM) is being increasingly applied at the 90nm node in addition with other mature resolution enhancement techniques (RETs) such as optical proximity correction (OPC) and sub-resolution assist features (SRAF). Several high-performance IC manufacturers already use alt-PSM technology in 65nm production. At 90nm having strong control over the lithography process is a critical component in meeting targeted yield goals. However, implementing alt-PSM in production has been challenging due to several factors such as
phase conflict errors, mask manufacturing, and the increased production cost due to the need for two masks in the process. Implementation of Alt-PSM generally requires phase compliance rules and proper phase topology in the layout and this has been successful for the technology node with these rules implemented. However, this may not be true for a mature, production process technology, in this case 90 nm. Especially, in the foundry-fabless business model where the foundry provides a standard set of design rules to its customers for a given process technology, and where not all the foundry customers require Alt-PSM in their tapeout flow. With minimum design changes, design houses usually are motivated by higher product performance for the existing designs. What follows is an in-depth review of the motivation to apply alt-PSM on a production FPGA, the DFM challenges to each partner faced, its effect on the tapeout flow, and how design, manufacturing, and EDA teams worked together to resolve phase conflicts, tapeout the chip, and finally verify the silicon results in production.
In this paper we describe, from the user's point of view, how Inverse Lithography Technology (ILT) differs from Optical Proximity Correction (OPC). We show simulation and experimental results from 90nm and 65nm semiconductor nodes, comparing ILT-generated masks and OPC-generated masks for real-life layouts, in a production environment. In addition, we discuss issues related to complexity and manufacturability of ILT-generated masks.
At the sub 90nm nodes, resolution enhancement techniques (RETs) such as optical proximity correction (OPC), phase-shifting masks (PSM), sub-resolution assist features (SRAF) have become essential steps in the post-physical verification 'Mask Synthesis' process and a key component of design for manufacturing (DFM). Several studies have been conducted and the results have been published on the implication and application of the different types of RETs on mask printability and costs. More specifically, double-exposure-based, dark-field, alternating PSM (Alt-PSM) technology has received lot of attention with respect to the mask manufacturing challenges and its implementation into a production flow, despite its yield and critical dimension (CD) control superiority.
Implementation of Alt-PSM generally requires phase compliance rules and proper phase topology in the layout and this has been successful for the technology node with these rules implemented. However, this may not be true for a matured, production process technology, in this case 90 nm. Especially, in the foundry-fabless business model where the foundry provides a standard set of design rules to its customers for a given process technology, and where not all the foundry customers require Alt-PSM in their tapeout flow. What follows is an in-depth review of the DFM challenges to each partner faced, its effect on the tapeout flow, and how design, manufacturing, and EDA teams worked together to resolve phase conflicts, tapeout the chip, and finally verify the silicon results in production.
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